Water-Cooled vs. Air-Cooled TIG Torches: The Definitive Guide

Water-Cooled vs. Air-Cooled TIG Torches: How to Pick the Right One Every Time

TIG welding is the gold standard for precision, cleanliness, and control—yet one overlooked choice can derail your entire project: picking between an air-cooled and a water-cooled TIG torch. Make the wrong call and you’ll wrestle with overheated torches, distorted tungsten, or an overpriced cart full of gear you never use.

In this master guide we’ll break down:

• Exact amperage and duty-cycle limits for each torch type

• Hidden costs most blogs skip (coolant, maintenance, downtime)

• Field-tested decision matrix used by AWS-certified welders

• 2025 buyer’s cheat-sheet: top torches, chillers, and quick-connect kits

---

What Separates Air-Cooled From Water-Cooled Torches?

Feature	Air-Cooled	Water-Cooled
Cooling medium	Ambient air + shielding gas flow	Recirculating coolant + shielding gas
Typical amperage ceiling	50–250 A (model dependent)	250–500 A+
Duty cycle	35–60 % at rated amps	100 % at rated amps
Torch head size	Larger to dissipate heat	Compact—heat goes to coolant
Cable weight	Heavier (thicker copper)	Lighter (smaller conductors)
Upfront cost	$85–$220 torch only	$350–$800 torch + cooler
Portability	Grab-and-go	Needs chiller cart or bucket
Maintenance	Hose & O-ring checks	Coolant, pump, radiator care

---

Deep Dive: Air-Cooled TIG Torches

How Air Cooling Actually Works

Air-cooled torches rely on two passive heat sinks:

1. Thick copper power conductors absorb resistive heat.

2. Shielding gas flow (argon, helium, or an Ar/He mix) carries heat away from the head.

There is no pump, radiator, or coolant loop—just physics.

When an Air-Cooled Torch Makes Sense

Application	Why Air-Cooled Wins
On-site repair (farms, pipelines)	No chiller to power or haul
Hobbyist aluminum artwork ≤ 3 mm	150 A is plenty
Classroom booths	Lower capital expense
Quick tacks on stainless tubing	Down-time between tacks = natural cooling

Pro tip: If your welder rarely pulls more than 150 A for 2 minutes straight, an air-cooled torch is the smart money.

Real-World Amperage & Duty Cycle Data

Model	Air-Cooled Rating	Continuous Weld Time @ Max Amps	Rest Needed
CK17	150 A DC, 60 % duty	3.6 min	2.4 min
WP-26	200 A DC, 60 % duty	3.0 min	2.0 min
Scratch-start import	130 A DC, 35 % duty	2.1 min	3.9 min

Field reality: Most welders overestimate their duty cycle. Logging your actual arc-on time with a stopwatch for one afternoon can save hundreds in unnecessary upgrades.

Downsides Nobody Mentions

• Cable stiffness – 1/0 copper weighs ~0.65 lb/ft; after 12 ft it fights you like a garden hose.

• Torch head bulk – A WP-26 head is ~30 % larger than a comparable water-cooled CK20, limiting tight-access joints.

• Heat fade – Tungsten erodes faster above 180 A because the collet runs hotter.

---

Deep Dive: Water-Cooled TIG Torches

How Water Cooling Works

A closed loop circulates coolant (usually distilled water + 20 % propylene glycol) through:

1. Torch head – absorbs arc heat.

2. Return line – feeds a radiator or chiller.

3. Pump – pushes cooled fluid back to the torch.

Result: torch body stays near ambient even at 400 A.

When a Water-Cooled Torch Is Non-Negotiable

Scenario	Required Amperage	Continuous Arc	Water-Cooled Justification
½" aluminum stack welds	350 A AC	8–10 min passes	100 % duty cycle prevents warpage
Automated circumferential pipe	280 A DC	30 min cycles	Air-cooled torch would melt cup & collet
Thick copper bus bar	450 A DC	5 min beads	Exceeds air-cooled thermal ceiling

2025 Chiller & Torch Pairings

Budget Tier	Torch	Cooler	Notes
Prosumer	CK20 (250 A)	Coolmate 3CS	1.6 gal tank, 1.0 GPM flow
Industrial	CK230 (300 A)	Procon 1 HP chiller	100 % duty @ 300 A, 2.3 GPM
Ultra-portable	WP-20 flex	North Slope NS-20	12 V DC option, fits truck inverter

Pro tip: Match flow rate not just amperage. A 0.7 GPM cooler on a 400 A torch starves the head and voids warranty.

Hidden Costs & Pain Points

• Coolant disposal – Propylene glycol is “non-toxic” but still banned from storm drains in CA, WA, NY.

• Pump cavitation – distilled water evaporates; low fluid = $200 pump replacement.

• Winter storage – 20 % glycol mix prevents freeze cracks to radiator.

---

Side-by-Side Comparison Table (2025 Lab Data)

Parameter	CK17 Air-Cooled	CK20 Water-Cooled
Max amps (DC)	150 A @ 60 % duty	250 A @ 100 % duty
Torch head Ø	1.02 in (26 mm)	0.87 in (22 mm)
Cable weight (12 ft)	3.9 lb	0.87 in (22 mm)
Tungsten stick-out before overheat	0.25 in	0.50 in
1-hr energy cost*	$0.06 (fan only)	$0.38 (pump + radiator)
5-year total cost of ownership	$260 (2 cups, 1 cable)	$580 (coolant, pump seal kit, descaler)

---

Decision Matrix: Choose in 90 Seconds

Answer three questions; follow the path.

1. Amperage > 200 A?
   Yes → Go to 2.
   No → Air-cooled.

2. Duty cycle > 60 % in one session?
   Yes → Water-cooled.
   No → Air-cooled.

3. Mobile or stationary?
   Mobile → Look at portable chillers (North Slope NS-20 or Coolmate 1).
   Stationary → Full-size chiller.

---

Installation & Setup Tips

Air-Cooled Quick Checklist

• Use 3/8 in gas hose minimum for 200 A to prevent back-pressure.

• Keep cable < 25 ft to reduce voltage drop.

• Tighten back-cap with collet-body wrench; finger-tight leaks gas.

Water-Cooled Quick Checklist

• Coolant mix: 3:1 distilled water to propylene glycol.

• Flow test: 1 gal jug should fill in ~45 s (≈ 1.3 GPM).

• Purge air: Run pump 2 min before first arc to avoid vapor lock.

  
  

---

Maintenance Schedules That Save You Money

Task	Air-Cooled	Water-Cooled	Interval
Inspect O-rings	✓	✓	Weekly
Check coolant level	—	✓	Daily
Flush & replace coolant	—	✓	6 months or 500 hrs
Descale radiator fins	—	✓	3 months
Cable flex test (kinks)	✓	✓	Monthly

---

Frequently Asked Questions (2025 Edition)

Q1. Can I convert an air-cooled torch to water-cooled?

No—cooling jackets, collet bodies, and caps are proprietary. Buy the correct torch.

Q2. How long can I run a 200 A air-cooled torch at 180 A?

≈ 3 minutes continuous, then 2 minutes rest. Log your arc-on time to confirm.

Q3. Is a 20 A 120 V circuit enough for a small chiller?

Yes—Coolmate 3CS draws 2.8 A continuous @ 120 V.